Posted 12th March 2003

Neil,

Here are the pictures I promised, showing how we packed our XL and Explorer for taking with us as luggage on an airplane. As you can see, we packed components that were not easily detachable in bubble wrap and taped them (with easy-release tape) to the frame. We strapped the frame and other parts SECURELY to the liner of the CrateWorks box, which has lots of holes just for that purpose. We cut a few more holes in the liner and bought a lot of extra Velcro tape. We fit each chain with a removable link so it would be easy to take apart. We put all the little stuff (pedals, mirrors, headrest, lights, etc.) into small plastic bags and these then went into a pannier, which went into the box. The trick is to pad and strap everything so that it cannot possibly shift, but there is no sense trying to fill the box with padding. That would just add to the weight, and it wouldn’t do any good. Strapping, not padding, is what makes it secure. We were right under the limit of 70 lbs, but as you see, we put helmets, panniers, even tools in the box. Once we were good at it, we could assemble or disassemble both trikes in about 2 to 2½ hours, working together.

We do not recommend purchasing the wheel caddy that you see in the picture because virtually every airport has large carts that you can use for luggage, so the extra wheels are just extra bulk and space. We also do not recommend the cardboard box (Pro 1), get the plastic one right away (Pro XL-C). Yes the cardboard stood up for one trip, but it was banged up. The plastic one, on the other hand, shows no signs that it was ever used. It’s very tough, very lightweight, and extremely well-priced.

Feel free to post or forward these pictures and my comments to anyone who is interested.

Mary Poppendieck

mary@poppendieck.com

Author of

Lean Software Development: An Agile Toolkit

www.leantoolkit.com

XL basic packing

XL partially packed

XL finished packed

Explorer basic packing

Explorer finish packed

Crateworks box